Dear Yamaha ATV Owner: Please Review this IMPORTANT SAFETY CARD before operating your ATV (If card is not attached, c% 800-344-6418). Dear New Yamaha ATV Owner: CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV. You have purchased a quality Yamaha product that, with proper use and care, will provide hours of riding pleasure. BEFORE YOU OPERATE YOUR NEW ATV, Yamaha recommends these Important points: ‘© READ YOUR OWNER'S MANUAL ‘© A.CHILD UNDER 42 YEARS OLD SHOULD NOT OPERATE AN ATV. WITH ENGINE SIZE 70CC OR GREATER ‘© A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC (© TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA — ASK YOUR DEALER FOR DETAILS OR CALL 1-800-887-2887 you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership, please fill out the information below and mail this card to Yamaha today. CAREFULLY Name: ATV Model: Purchase Date: _ a wo TON ve Address Primaty LO Agine Number: a i tr et TEE -/iL Beater Name & Adress: wi Telephone: cc C4 =NO POSTAGE NECESSARY IF MAILED. INTHE UNITED STATES BUSINESS REPLY MAIL FIRSTCLASS ___PERMITNO.4 __CYPRESS, CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U.S.A. P.O. BOX 6555 CYPRESS, CALIFORNIA 90630-9989 ATTN: SALES ADMINISTRATION WadacllocsellecseldabesalaleelsteaealabateeleallEDAZ0002 INTRODUCTION Congratulations on your purchase of the Yamaha YFM350U. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace- setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and opera- tion of this machine. This manual includes important safety information. It provides infor- mation about special techniques and skills necessary to ride your machine. It also includes basic maintenance and inspection procedures. If you have any questions regarding the op- eration or maintenance of your machine, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: @ READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR MACHINE. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. @ PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MACHINE. @ NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-447-4700 FOR MORE INFORMATION. @ THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.EDAT0001 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following nota- tions: a The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Wc) Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine. IONE ©: A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: ANOTE provides key information to make procedures easier or clear- er.EDA20100 IMPORTANT NOTICE This machine is designed and manufactured for OFF-ROAD use only. Itis illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this machine. EDAD0000 AFFIX DEALER LABEL HERE EDADO100 YFIM350UK OWNER’S MANUAL © 1997 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 1997 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan P/N LIT-11626-10-87EDA2S001 A WARNING Indicates a potential hazard that could re- sult in serious injury or death. CONTENTS LOCATION OF THE “WARNING AND SPECIFICATION LABELS” .....1-1 SAFETY INFORMATIO! | 3 | DESCRIPTION AND MACHINE IDENTIFICATION... Identification numbers record .. Key identification number.. Vehicle identification numbe: Model label... g CONTROL FUNCTIONS Main switch Indicator lights. Oil temperature indicator light checking method. Speedometer Handlebar switches. 4-4 Throttle lever.. Speed limiter. Front brake lever Rear brake pedal and lever. Parking brake Shift pedal... Drive select lever .. Recoil starter . Fuel tank cap. Fuel cock. Starter “CHOKE” Seat... Storage box. Front carrier. Rear carrier.PRE-OPERATION CHECKS.. OPERATION .. Front shock absorber adjustment Rear shock absorber adjustment... Auxiliary DC terminal Front and rear brakes . Throttle lever. Fittings and Fasteners How to measure tire pressure Tire wear limit Starting a cold engine Starting a warm engine. [7 | RIDING YOUR MOTO-4 .. Warming up. Drive select lever operation and reverse driving. Reverse lock release wire Shifting .... To start out and accelerate... To decelerate Engine break-in Parking Parking on a slope. Accessories and loadin Getting to know your MOTO- Ride with care and good judgement. Be careful where you ride Turning your MOTO-4.. Climbing uphill Riding downhill. Crossing a slope. Crossing through shallow waterRiding over rough terrain. Sliding and skidding What to do if What to do. PERIODIC MAINTENANCE AND. ADJUSTMENT... Owner's manual and tool kit Periodic maintenance/ lubrication Spark plug inspection Air filter cleanin: Carburetor adjustment Idle speed adjustment Valve clearance adjustment Select lever safety system cable adjustment. Throttle lever adjustment. Front brake shoe inspection Rear brake shoe inspection... Inspecting the brake fluid level ..8-19 Brake fluid replacement.. Front brake lever free play adjustment... Rear brake pedal and lever adjustment Clutch adjustment .. Cable inspection and lubrication . Brake and shift pedals/brake lever lubrication Wheel removal. Wheel installation. Battery.. Replenishing the battery fluid Fuse replacement... Replacing the headlight bulb Headlight beam adjustment Troubleshooting .. Troubleshooting chart.CLEANING AND STORAGE... A. Cleaning B, Storag SPECIFICATIONS... NOISE REGULATION .. MAINTENANCE RECORD... MOTO-4 LIMITED WARRANTY ....13-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ..EDAAOO00 LOCATION OF THE “WARNING AND SPECIFICATION LABELS”Read and understand all of the labels on your machine. They contain important in- formation for safe and proper operation of your MOTO-4. Never remove any labels from your MOTO-4. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 40 kg (88 Ibs) YAMAHA Teena A WARNING NEVER sit here YaMATA 267500, 12 A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. [LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE : Sot with tros old "Recommended : FRONT: 2kPa, (0. 204gler, 2. 9p EAR 20xPs, (0 20kgem, 2 dst ‘© Moirum FRONT! TraPa,(.174glem, 256s) REAR 17aPa, (0.1 7am), 2 pet «Never set ce proasure below minimum. hood cause {he te te csiodge fom tha en Seige ater ca aac abit and nang. Fad owners mantel bore loach o owing * Rodos spats'and ai more room to sop. ‘Avalos ar ough erin «+ Maxum Vorile Load 21g, (463 bs) Ireudes weight a operat cafQs ard accossoies (ant appieabe, water ongue weigh. A WARNING NEVER ride as aj passenger, Passengers can cause| resulting in SEVERE INJURY or DEATH. a loss of control, || |YAMAHA foot brake YAMA 80 kg (176 Ibs) 48124097-00 «# Shiting in overs i impossible without ppg | ‘aN2T870-00 DRIVE SELECT LEVER [Read owners manval carey belore operating ATV MUST be stopped Bolo shiing sole 13 A WARNING Improper ATV use can result In SEVERE INJURY or DEATH. BOe® AAS USE NEVER USE NEVER CARRY EVER Use AMUAPPROVED OW SINGERS. TH DRUG eIMET AND Sr aueoHe PROTECTIVE ‘cEAR NEVER operate : + without ‘proper training or Instruction. at speeds too fast for your skills or the conditions. + on public roads-a collision can occur with another vehicle. ‘+ with @ passenger-passengers attect balance and steering and increase risk of losing control. ALWAYS : ‘use proper riding techniques to avold vehicle overturns on hills and rough terrain and in turns, wold paved surfaces-pavement may serlously affect handling and control. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558)A WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death, NEVER operate this ATV if you aro under age 16. YAMAHA 14OAR0001 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differ- ently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obsta- cles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures de- scribed. © Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-447-4700 to find out about the training courses nearest you. © Always follow the age recommendation: —Achild under 16 years old should never operate an ATV with engine size greater than 90ce. © Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely. Never carry passenger on an ATV. @ Always avoid operating an ATV on any paved surfaces, including sidewalks, drive- ways, parking lots and streets.Never operate an ATV on any public street, road or highway, even a dirt or gravel one. Never operate an ATV without wearing an approved motorcycle helmet that fits prop- erly. You should also wear eye protection (goggles or face shield), gloves, boots, long- sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. Always inspect your ATV each time you use it to make sure it is in safe operating con- dition. Always follow the inspection and maintenance procedures and schedules de- scribed in this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be espe- cially cautious on these kinds of terrain. Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at exces- sive speed. 22© Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. © Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slip- pery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed. © Always follow proper procedures for going down hills and for braking on hills as de- scribed in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. © Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible. © Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. 23© Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. © Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery sur- faces, such as ice, go slowly and be very cautious in order to reduce the change of skidding or sliding out of control. © Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings. @ Always be sure there are no obstacles or people behind you when you operate in re- verse. When it is safe to proceed in reverse, go slowly. © Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual. Never modify an ATV through improper installation or use of accessories. @ Never exceed the stated load capacity for an ATV. Cargo should be properly distribut- ed and securely attached. Reduce speed and follow instructions in this manual for car- rying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Com- mission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344. 24POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refuel- ing. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or while in the vicinity of sparks, open flames, or other sources of ignition such as the pi- lot lights of water heaters and clothes dryers. When transporting the machine in an- other vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause in- juries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your machine in an area with adequate ventilation. 26EDASO000 DESCRIPTION AND MACHINE IDENTIFICATION 1. Rear carrier 11. Shift pedal 2. Seat 12. Drive select lever 3. Front carrier, 13, Front wheel 4, Rear brake pedal 14, Rear brake lever 5. Reverse lock release 15. Parking brake wire 16. Speedometer 6. Headlight 17. Front brake lever 7. Fuel cock 18. Throttle lever 8. Starter “CHOKE” 19. Main switch 9. Recoil starter 20. Handlebar switch 10. Rear wheel NOTE: The machine you have purchased may dif- fer slightly from those shown in the figures of this manual. a4opens Identification numbers record Record the key identification number, ve- hicle identification number and model la- bel information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 2. VEHICLE IDENTIFICATION NUMBER: 3. MODEL LABEL INFORMATION: O° e 32 paso20 Key identification number The key identification number is stamped on the key as shown in the following illus- tration. This number can be used for order- ing a new key. 1. Key identification numberEDA80000 Vehicle identification number The vehicle identification number is stamped into the frame. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 33 oaror00 Model label The model label is affixed to the frame. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Model label0800000 CONTROL FUNCTIONS Indicates a potential hazard that could re- sult in serious injury or death. oecoi0 Main switch Functions of the respective switch posi- tions are as follows: ON: Engine can be started only at this position and the headlight and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position. 4 OFF, ONob1000 Indicator lights |. Reverse indicator light “REVERSE” 2. Neutral indicator light “NEUTRAL” 3. Oil temperature indicator light “OIL TEMP” 0810600 Reverse indicator light “REVERSE” This indicator light comes on when the transmission is in reverse. dicator light “NEUTRAL” This indicator light comes on when the transmission is in neutral. 42 epstoe00 Oil temperature indicator light “OIL TEMP” When the oil temperature reaches a speci- fied level, this light comes on to warn that the engine has overheated. If the light comes on during operation, stop the en- gine as soon as it is safe to do so and allow the engine to cool down for about 10 min- utes. 1. The light comes on mostly due to overload. Reduce the load to specifi- cation before restarting the engine. 2. Restart after making sure that the light is out. Continuous use while the light is on may cause damage to the engine.epazsscz Oil temperature indicator light checking method Turn the main switch to “ON” and the engine stop switch to “RUN”. be a Oil temperature indicator light does not come on. 1 Push starter switch with the transmission in neutral. ct Oiltemperature indicator light comes on. 1 Check engine oil temperature. a Oil temperature indi-| { Oil temperature indicator cator light comes on.| | light does not come on. Oil tempera-] {Oil tempera- ture is low. | | ture is high. — Engine oil temperature and electrical circuit are inspect the electrical circuit. Ask a Yamaha dealer to Allow to cool. OK. Go ahead with riding. 43eoesceco Speedometer The speedometer shows riding speed. This speedometer is equipped with an odometer and trip odometer. The trip odometer can be reset to “0” with the re- set knob. Use the trip odometer to esti- mate how far you can ride on a tank of fuel. This information will enable you to plan fuel stops in the future. 2. Odometer 4, Reset knob 1. Speedometer 3. Trip odometer 44 eD88000 Handlebar switches 1, Lights switch "LIGHTS" 2. Engine stop switch "ENG STOP" +3. Start switch “START” epessio0 Engine stop switch “ENG. STOP” Make sure that the engine stop switch is in the “RUN” position. The engine stop switch has been equipped to ensure safety in an emergency such as when the ma- chine is upset or trouble takes place in the throttle system. The engine will not start or run when the engine stop switch is turned to “OFF”.vesssor Start switch “START” The starter motor cranks the engine when this switch is pushed. See starting instructions prior to starting engine. (see page 6-1 for details) 0ass001 Lights switch “LIGHTS” Turn the switch to “LO” for the low beam and taillight. Turn the switch to “HI” for the high beam and taillight. Do not use the headlight with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge ipseos00 Throttle lever Once the engine is running cleanly, move- ment of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. 1, Throttle lever 46 Before starting the engine, check the throt- tle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. A_WARNING POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can't find or solve the problem yourself.0880100 Speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum. Screwing in the adjuster lowers the engine power available and decreases the maximum speed of the ATV. 1. Locknut 2. Adjuster a. 12mm (0.47 in) 47 A_WARNING POTENTIAL HAZARD Improper adjustment of the speed limit- er and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could re- sult. You could lose control, have an ac- cident or be injured. HOW TO AVOID THE HAZARD Do not turn the speed adjuster out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3 ~5 mm (0.12 ~ 0.20 in). See page 8-17.000000 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Front brake lever peso%00 Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever is locat- ed on the left handlebar. Push down on the pedal or pull the lever toward the handle- bar to apply the rear brake. 1. Rear brake lever>es0400 ’arking brake Jse the parking brake when you have to start the engine or park the machine, espe- sially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake le- ver to release the parking brake. 1. Lock plate 49 A_WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpect- edly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prema- turely. HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine. Always be sure you have released the parking brake before you begin to ride.880000, Shift pedal This machine is equipped with a constant- mesh 5-speed transmission. The shift ped- al is located on the left side of the engine. Neutral is at the bottom position. 0895000 Drive select lever The drive select lever is used to shift your machine into high, low or reverse. Refer to page 6-4 for the drive select lever opera- tion. 1. Shift pedal N. Neutral 1. Drive select lever a. High b. Low ©. Reverse25000 ecoil starter irmly grasp the handle and pull slightly intil engagement can be felt. Then pull orcefully, being careful not to pull the ‘ope all the way out. 1, Recoil starter CN SNMey POTENTIAL HAZARD Starting tl ngine in gear and/or start- ing the engine without setting the park- ing brake. WHAT CAN HAPPEN The ATV could start to move unexpect- edly, which could cause an accident. HOW TO AVOID THE HAZARD Put the transmissi neutral and set the parking brake before starting the engine.zocontea Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1, Fuel tank cap eo ct0001 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: ON: RES: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. This indicates reserve. If you run out of fuel while riding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY. After refuelling, return the fuel cock lever to the “ON” position.vca0zt2 Starter “CHOKE” Starting a cold engine requires a richer air- fuel mixture. A separate starter circuit sup- plies this mixture. Pull the starter “CHOKE” out to open the circuit for start- ing. When the engine has warmed up, push the starter “CHOKE” in to close the circuit. Refer to “Starting a cold engine” for proper operation. 413 1. Fully-open 2. Half open 3. Closed a. Starter “CHOKE”epc40001 Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. 1. Seat lock lever To install the seat, insert the lobe on the seat front into the receptacle on the frame and push down the seat at the rear. NOTE: —__________ Make sure that the seat is securely fitted.>oseo00 Eopen009 itorage box Front carrier Maximum load limit: 2 kg (4.4 Ibs) Maximum load limit: 40 kg (88 Ibs) 5 — immnrito To protect from damage, do not put metal Rear carrier products, like tools or sharply edged prod- ucts directly in the storage box. If they Maximum load limit: 80 kg (176 Ibs) must be stored, wrap them in appropriate 415pce Front shock absorber adjustment The spring preload can be adjusted to suit the rider's weight and riding conditions. Spring preload adjustment To increase the spring preload, turn the ad- juster in direction @. To decrease the spring preload, turn the a. Increase spring preload b. Decrease spring preload Standard position: A A-— Minimum (Soft) E — Maximum (Hard) 4 WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set- ting.EDc90s01 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Spring preload adjustment Standard position: A A- Minimum (Soft) E — Maximum (Hard) To increase the spring preload, turn the ad- juster in direction @. To decrease the spring preload, turn the adjuster in direction ®. ‘a, Increase spring preload b. Decrease spring preload 47oore000 Auxiliary DC terminal The auxiliary DC terminal is located on the front carrier. The auxiliary terminal can only be used when the main switch is on and the engine is running. Refer to the following chart for correct usage. o\ |! 1. Auxiliary DC terminal AMPERAGE CHART. = RIDING SPEED ~~ IDLING SPEED | (3,000 r/min. or more) HEAD/TAIL LIGHT “on” {Cannot be used.| — 12V, 5A HEAD/TAIL LIGHT “OFF* 12V, 5A 12V, 104, @ If accessories are used in excess of the above capacity, or if accessories are used with the engine not running, the battery will lose its charge and engine ‘starting may become icult. @ Do not use accessor requiring more than 12V, 10A. This may over- load the circuit and cause a fuse to blow.3onnecting accessory leads 1. Strip off 5 mm of insulation from each accessory lead. Twist the stranded wires. 2. Pass the leads through the protective cover, then crimp a terminal onto each lead. Securely connect the leads. a 5mm 1. Accessory plug 2. Cover Take note of the marks embossed on the accessory plug. Make sure that the posi- tive and negative lead are connected to the corresponding terminal. Make sure that neither terminal is shorted. 3. Put the protective cover over the ac- cessory plug. 1. Accessory plug 2. CoverHow to use the Auxiliary DC terminal 3. Insert the accessory plug into the re- 1. Start the engine (see page 6-1). ceptacle and secure it with the screw- 2. Remove the dust cap from the recep- on cap. tacle. lo =a \\)! 1. Receptacle 2. Accessory plug 1. Dust cap 4. When the accessory terminal is not being used, screw the dust cap onto the receptacle for protection. 4-20eDE00001 AWARNING Indicates a potential hazard that could result in serious injury or death.PRE-OPERATION CHECKS Before using this machine, check the following points: TEM ROUTINE PAGE + Check operation, free play, fluid level and fluid leakage ooeenenes + Top-up with DOT 4 (or DOT 3) brake fluid if necessary. ea bh Rear brake * Check operation, lever/pedal free play and pedal height. + Check fuel level. Fuel tank + Top-up as required. 55 ~66 * Check level. Engine oil + Top-up as required. 5-7,85~89 Final gear oil + Check for leakage. 5-8, 8-9 ~ 8-11 Throttle + Check for proper throttle cable operation. 58, 8.17 a 7 5-9 ~ 5-12, Wheels and tires + Check tire pressure, wear and damage. 220-830 Fittings and fasteners | + Check all fittings and fasteners. 5-8 Lights * Check for proper operation. 5-8, 8-37 ~ 8-38 Battery * Check fluid level. + Top-up with distilled water if necessary. 5-8, 8-31 ~ 8-34 51PEGs POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV. WHAT CAN HAPPEI increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and main- tenance procedures and schedules de- scribed in the Owner's Manual. 52£0E11201 Front and rear brakes 1. Brake levers and brake pedal Check for correct free play in the brake levers and brake pedal. If the free play is incorrect, adjust it. See pages 8-21 ~ 8-26. Check operation of the levers and ped- al. They should move smoothly and there should be a firm feeling when the brake is applied. If not, have the machine inspected by a Yamaha dealer. . Brake fluid level (Front brake) Check the brake fluid level. Add fluid if necessary. See pages 8-19 ~ 8-20. Recommended brake fluid: DOT 4 NOTE:. If DOT 4 is not available, DOT 3 can be used. 53 3. Brake fluid leakage Check to see if any brake fluid is leak- ing out of the hose, joint or master cyl- inder of the front brake. Apply the brake firmly for one minute. If the le- ver moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be inspected by a Yamaha dealer. . Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brakes for wear (see pages 8-18 ~ 8-19).A_WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the ad- justment procedures provided in this manual, have the ATV inspected by a Yamaha dealer. 54ocs000+ Fuel Make sure there is sufficient gasoline in the tank. Recommended fuel: UNLEADED FUEL Fuel tank capaci Total: 10.0 L (2.2 Imp gal, 2.6 US gal) Reserve: 1.3 L (0.29 Imp gal, 0.34 US gal) Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ((R+M)/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium un- leaded fuel. Unleaded fuel will give you longer spark plug life and reduced mainte- nance cost. If unleaded gasoline is not available, then leaded regular gasoline can be used. 55 Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle per- formance problems. 1. Fuel level 2. Filler tubePOTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the f not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot. 560e30203 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See page 8-5 ~ 89.) Recommended oil: , Pod | YAMALUBE 4 (20W40) or SAE 20W40 | —eseCeGOo“_ 9 1p 3p spr 7p gor TDF | ‘YAMALUBE 4 (1pW20) or SAE 19W30_ | SAE SWy30 20° -10° 10° 20° 30° 40°C Recommended engine oil classification: API Service “SE”, “SF” type or equivalent (e.g. “SF-SE”, “SF-SE-CC”, "SF-SE-SD" etc.) 57 Oil quantity: Periodic oil change: 2.4L (2.1 Imp qt, 2.5 US qt) With oil filter replacement: 2.8 L (2.5 Imp qt, 3.0 US qt) Total amount: 3.2 L (2.8 Imp at, 3.4 US qt)Dot0100 Final gear oil Make sure the final gear oil is at the speci- fied level. Add oil as necessary (see pages 8-9 ~ 8-11 for details). Recommended oil: SAE 80 API GL-4 Hypoid gear oil If desired, an SAE 80W90 hypoid gear oil may be used for all conditions. NOTE; GL-4 is a quality and additive rating, GL-5 or GL-6 rated hypoid gear oils may also be used. evestico Throttle lever Check to see that the throttle lever oper- ates correctly. It must open smoothly and spring back to idle position when released. Repair as necessary for proper operation. 58 95001 Fittings and Fasteners Always check the tightness of chassis fit- tings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. 070000 Lights Check the headlight and taillight to make sure they are in working condition. Repair as necessary for proper operation. e0e70100 Switches Check the operation of the headlight switch, engine stop switch and any other switches. Repair as necessary for proper operation. 0e70201 Battery Check fluid level and top-up if necessary. Use only distilled water if refilling is neces- sary. See pages 8-31 ~ 8-34.EDE90000 Tires POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pres- sure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD 1. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model, Other tire com- binations are not recommended. | Manufacturer ‘Size Type Front | CHENG SHIN, | AT25x8-12 | C9207 Roser | CHENGSHIN, | AT25x129 | C9209 59 2. The tires should be set to the rec- ommended pressure: @ Recommended tire pressure Front 20 kPa (0.20 kgf/cm2, 2.9 psi) Rear 20 kPa (0.20 kgf/cm7, 2.9 psi) © Check and adjust tire pressures when the tires are cold. ire pressures must be equal on both ides. ire pressure below the minimum specified could cause the tire to dis- lodge from the rim under severe riding conditions. The following are minimums: Front 17 kPa (0.17 kgf/cm2, 2.5 psi) Rear 17 kPa (0.17 kgf/cm?, 2.5 psi)4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm?, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slow- ly and carefully. Fast inflation could cause the tire to burst.090200 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measure- ments of the tire pressure and use the sec- ond reading. Dust or dirt in the gauge could cause the first reading to be incor- rect. 1. Low-pressure tire gauge Set pressure with tires cold. Set tire pressures to the following specifi- cations: [Recommended] Winimum | Maximum pressure 20 kPa 17 kPa 23 kPa Front | (0.20 kaf/em?, | (0.17 kgf/cm’, | (0.23 kgf/cm”, 29 psi) 25 psi) 3.3 psi) 20 kPa 17 KPa 23 kPa Rear | (0.20 katicm?, | (0.17 kafiem?, | (0.23 kgtlom?, 29 psil 2.5 psi) 3.3 psi)veo Tire wear When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. 3mm (0.12 in) B12eDF00100 OPERATION AWARNING Indicates a potential hazard that could re- sult in serious injury or death. 4_WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner's Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer. 61 EoFr2t02 Starting a cold engine A WARNING POTENTIAL HAZARD Freezing control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or colli- sion. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin 1, Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “RUN”. 3. Shift the transmission into neutral.NOTE: @ When the transmission is in neutral, the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. The engine can be started with the transmission and drive select lever in any position if the rear brake lever is applied. However, it is recommended to shift into neutral before starting the engine. 4, Use the starter “CHOKE” in reference to the figure: Position © : Cold engine start- ambient temperature below 5°C (40°F). :Cold engine start- ambient temperature at 0°C (30°F) ~ 30°C (90°F) and warm- ing up position. Position @ Position @ : Cold engine start- ambient temperature above 28°C (80°F) and warm engine start position. AMBIENT TEMP/STARTER “CHOKE” POSITION 20° 30° °c ro oF ® Oss o” — 10° } ey a0 eZ 5. Completely close the throttle lever and start the engine by pushing the start switch. 62NOTE: © If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next at- tempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. If the battery is discharged, pull the re- coil starter to start the engine. . If the engine is started at position ©, the starter “CHOKE” should be re- turned to position © (half-open) to warm up the engine. If the engine is started at position @, keep it at this position to warm up the engine. . Continue warming up the engine until it idles smoothly and return the starter “CHOKE” to position © (closed) be- fore riding. 63 See the “Engine break-in” section prior to operating engine for the first time. eprtoea2 Starting a warm engine To start a warm engine, refer to the “Start- ing a cold engine” section. The starter “CHOKE” should not be used. The throttle should be opened slightly. orto Warming up To get maximum engine life, always warm up the engine before starting off. Never ac- celerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter “CHOKE” turned off.E0F20701 Drive select lever operation and reverse driving Before shifting, you must stop the ma- chine and return the throttle lever to the closed position. Otherwise, the transmis- sion may be damaged. 1. Shifting: High ~ Low. a. Bring the machine to a complete stop = Mish oe aes and return the throttle lever to the c. Open the throttle lever gradually. closed position. b. Shift from high to low and vice versa by moving the shift lever along the shift guide. NOTE; Make sure that the lever is completely shifted into position.2. Shifting: Low ~ Reverse NOTE: 1. The select lever cannot be shifted into reverse from low without applying the rear brake pedal. 2. Shifting into reverse can be done with the transmission in any gear. a. Bring the machine to a complete stop and return the throttle lever to the closed position. b. Apply the rear brake pedal. c. Shift from low to reverse and vice ver- sa by moving the shift lever along the shift guide. NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the ma- chine. a. High blow ce Reverse d. Check behind for people or obstacles, then release rear brake pedal. e. Open the throttle lever gradually and continue to watch to the rear while backing.A_WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person be- hind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly. 66 eorsoaco Reverse lock release wire If the machine should get stuck in obsta- cles such as rocks, making it impossible for the rear brake pedal to applied, pull the re- verse lock release wire to shift into reverse gear. Reverse lock release wireShifting This model is equipped with a dual, 5- speed forward and 1-speed reverse trans- mission with a centrifugal clutch. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, reverse, etc. To shift into neutral, return the throttle lever to its orig- inal position and repeatedly depress the shift pedal until it stops. 1. Shift pedal N. Neutral 67 _ CAUTI Do not coast for long periods with the en- gine off, and do not tow the machine a long distance. Even in neutral position, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may cause damage. DF20400 To start out and accelerate: 1. Release the throttle lever. Always close the throttle while shifting gears. Otherwise, damage to the engine and drive train may result. 2. Shift into first gear and release the shift pedal. 3. Open the throttle gradually.4. Once the machine has attained ade- quate speed, release the throttle lever. 5. Shift into second gear and release the shift pedal. 6. Open the throttle gradually. 7. Follow the same procedure when shifting to the next higher gear. A_WARNING POTENTIAL HAZARD Opening the throttle before releasing the shift pedal. WHAT CAN HAPPEN The machine could wheelie. This would increase the chance of an accident, in- cluding overturn. HOW TO AVOID THE HAZARD Release the shift pedal before opening the throttle. Open the throttle gradual- ly. eoFzosa0 To decelerate: When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a low- er gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possi- bility of an accident. PGI) POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently ing to a lower gear.epresico Engine break-in There is never a more important period in the life of your machine than the period be- tween zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle operation or any condition which might re- sult in excessive engine heating must be avoided. However, momentary (2 ~ 3 sec- onds maximum) full throttle operation un- der load does not harm the engine. 69 Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer. 1. 0~ 10 hours: Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to time. Do not op- erate it at one set throttle position.oreo 2. 10 ~ 20 hours: Parking Avoid prolonged operation above 3/4 — When parking, stop the engine and shift throttle. Rev the machine freely into neutral. Turn the fuel cock to “OFF” through the gears but do not use full and apply the parking brake. throttle at any time. 3. After break-in: Avoid prolonged full throttle opera- tion. Vary speeds occasionally. 1. Lock plateepreczao Parking on a slope A_WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, in- creasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. Hf you must park on an incline, put the machine in low gear, apply the parking brake, and block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily. . Bring the machine to a stop by apply- ing the brakes in low gear. . Stop the engine. . With the rear brake lever and pedal ap- plied, apply the parking brake and slowly release the rear brake pedal.orso00n Accessories and loading eore0100 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. © Choose only accessories designed for your ATV. Your Yamaha dealer has a va- riety of genuine Yamaha accessories. Other accessories may also be available on the market. However, it is not possi- ble for Yamaha to test all non-Yamaha accessories, nor have any control over the quality or suitability of them. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality. 612 © Accessories should be rigidly and se- curely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV. Do not mount an accessory where it could interfere with your ability to con- trol the ATV. Examples include (but are not limited to) a heavy or bulky object at- tached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view. Use extra caution when riding an ATV with accessories. The ATV may handle differently than it does without accesso- ries.prsozot Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgement when carrying cargo or towing a trailer. Keep the following points in mind: © Never exceed the weight limits shown. An overloaded ATV can be unstable. MAXIMUM LOADING LIMIT Vehicle loading limit (total weight of cargo, rider and accessories, and tongue weight): 210 kg (463 Ibs) Front carrier: 40 kg (88 Ibs) e e Rear carrier: 80 kg (176 Ibs) @ Storage box: 2 kg (4.4 Ibs) @ Trailer hitch: Pulling load (total weight of trailer and cargo}: 410 kg (904 Ibs) Tongue weight (vertical weight on trailer hitch point): 18 kg (33 Ibs) 613 © Do not exceed the maximum tongue weight. You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Adjust the load in the trailer, if necessary, to reduce the weight on hitch. If you are carrying cargo and towing a trailer, include the tongue weight in the maximum vehicle load limit. Load cargo on the carrier as close to the center of the vehicle as possible. Put car- go at the front of the rear carrier. Center the load from side to side. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. Make sure the load does not interfere with controls or your ability to see where you are going.© Ride more slowly than you would with- out a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range 2nd gear whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. © Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. CWT eI POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle han- dling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.eFsso03 A WARNING Indicates a potential hazard that could re- sult in serious injury or death. 61572AWARNING Indicates a potential hazard that could re- sult in serious injury or death. GETTING TO KNOW YOUR MOTO-4 This MOTO-4 is mainly for utility use, but may also be used for recreation. This sec- tion, Riding your MOTO-4, provides gener- al ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your MOTO-4 requires special skills acquired through practice over a period of time. Take the time to learn the basic techniques well be- fore attempting more difficult maneuvers. Riding your new MOTO-4 can be a very en- joyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the MOTO-4 73 to achieve the skill necessary to enjoy riding safely. Before you begin to ride be sure you have read this Owner's Manual completely and understand the operation of the controls. Pay particular attention to the safety information on page 2-1 ~ 2-6. Please also read all caution and warning labels on your MOTO-4.RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. Beginners should get training from a certi- fied instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the machine's handling and performance characteristics. POTENTIAL HAZARD Operating this ATV without proper struction. WHAT CAN HAPPEN The risk of an accident is greatly in- creased if the operator does not know how to operate the ATV properly in dif- ferent situations and on different types of terrain. 14 HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating tech- niques described in this Owner's Manu- al. For more information about the training course, contact an authorized ATV dealer or call 1-800-447-4700. Riding your machine requires skills ac- quired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult ma- neuvers.Not recommended for children under 16 years of age. POTENTIAL HAZARD Failure to follow the age recommenda- tions for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90ce. 15This machine is designed to carry operator and cargo only - passengers prohibited. POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an ac- cident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.Apparel POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye pro- tection and protective clothing. WHAT CAN HAPPEN Operating without Prowcive an approved motor- “ina Goggles cycle helmet in- creases your Helmet loves chances of a severe | head injury or death A in the event of an i accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. Boots 1 Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants.Do not operate after consuming alcohol or drugs. Operator's performance capability is re- duced by the influence of alcohol or drugs. Ne) POTENTIAL HAZARD Operating this ATV after consuming al- cohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and percep- tion. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.Pre-Operation checks Always perform the Pre-Operation checks listed on page 5-1 before riding for safety and proper care of the machine. PGs POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each ti use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's e you Manual. 79 PRINT POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pres- sure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an acci- dent. HOW TO AVOID THE HAZARD Always use the size and type tires spec- ied in the Owner's Manual for this ve- cle on page 5-9 ~ 5-10. Always maintain proper tire pressure as de- scribed in the Owner's Manual on page 5-11.WARNING Indicates a potential hazard that could re- sult in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. PRG POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an acci- dent. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating con- ditions, and your experience. Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits the power and top speed of the machine. Turning the screw in de- creases top speed, and turning it out in- creases top speed. 1. Locknut 2. AdjusterLoading and accessories Use extra caution when riding the machine with additional loads, such as accessories or cargo. The machine's handling may be adversely affected. Reduce your speed when adding additional loads. MAXIMUM LOADING LIMIT e Vehicle loading limit (total weight of cargo, rider and accessories, and tongue weight): 210 kg (463 Ibs) @ Front carrier: 40 kg (88 Ibs) @ Rear carrier: 80 kg (176 Ibs) © Storage box: 2 kg (4.4 Ibs) @ Trailer hitch: Pulling load (total weight of trailer and cargo): 410 kg (904 Ibs) Tongue weight (vertical weight on trailer hitch point): 15 kg (33 Ibs) A_WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle han- dling which could lead to an accident. HOW TO AVOID THE HAZARD. Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owner's Manual for carrying cargo or pulling a trailer.During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. 712 A_WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re- duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handle- bars and both feet on the footboards of your ATV during operation.Avoid wheelies and jumping. You may lose control of the machine or overturn. POTENTIAL HAZARD Attempting wheelies, jumps, and other ‘stunts. WHAT CAN HAPPEN Increases the chance of an accident, in- cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off. 713Modifications 4A_WARNING POTENTIAL HAZARD Operating this ATV with improper mod- ifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improp- er installation or use of accessories. Alll parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized ATV dealer.Exhaust system The exhaust system on the machine is very hot during and following operation. To prevent burns, avoid touching the ex- haust system. Park the machine in a place where pedestrians or children are not like- ly to touch it. POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Someone touching the exhaust system during or after operation could be burned. HOW TO AVOID THE HAZARD Do not touch the hot exhaust system. Do not park the machine in a place where others might be likely to touch it.BE CAREFUL WHERE YOU RIDE: This machine is designed for off-road use only. Riding on paved surfaces can cause loss of control. A_WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATV's are designed for off-road use only. Paved surfaces may seriously af- fect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. 716Do not ride on any public road, street, or highway. Riding on public roads can result in colli- sions with other vehicles. POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.Know the terrain where you ride. Ride cau- tiously in unfamiliar areas, Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the machine to upset. POTENTIAL HAZARD Failure to use extra care when operat- ing this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV over- turning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when op- erating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. 718POTENTIAL HAZARD Failure to use extra care when operat- ing on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an acci- dent, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills neces- sary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the machine. DO NOT use the flag pole bracket as a trailer hitch, POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles. WHAT CAN HAPPEN You could be in a coll injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ma- chine to make you more visible. Watch carefully for other vehicles. n. You could be Do not ride in areas posted “no trespass- ing”. Do not ride on private property with- out getting permission.Select a large, flat area off-road to become familiar with your MOTO-4. Make sure that this area is free of obstacles and other rid- ers. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before try- ing more difficult terrain. Always avoid riding on paved surfaces: the MOTO-4 is designed for off-road use only, and han- dling maneuvers are more difficult to per- form on pavement. Set the parking brake and follow the in- struction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your MOTO-4. As you get on the MOTO-4, be sure not to accidentally move the shift pedal. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components. With the engine idling, lift the shift pedal to the 1st gear position and then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. Once the MOTO-4 has attained adequate speed, release the throttle and lift the shift pedal to the 2nd gear position. Release the shift pedal and apply the throttle smoothly. Use this same procedure as you move into the higher gears. Be sure to coordinate the use of the throttle and shift pedal properly. If the throttle is applied too abruptly or if the throttle is not released during shifting, or if the shift pedal is not released before applying the throttle, the front wheels may lift off the ground resulting in a loss of di- rectional control. Avoid higher speeds un- til you are thoroughly familiar with the operation of your MOTO-4.Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a low- er gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possi- bility of an accident. PGI) POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD has sufficiently slowed before shifting to a lower gear.TURNING YOUR MOTO-4 To achieve maximum traction while riding off-road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the MOTO-4 will re- sist turning. A special turning technique must be used to allow the MOTO-4 to make turns quickly and easily. It is essen- tial that this skill be learned first at low speed. POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner's Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions. ‘As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the outside of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even speed through the turn. This maneuver will let the wheel on the inside of the turn slip slightly, allow- ing the MOTO-4 to make the turn properly.Support your 1 weight on the This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your MOTO-4 may continue to go straight. If the MOTO-4 doesn’t turn, come to a stop and then practice the procedure again. If the riding surface is slippery or loose, it may help to position more of your weight over the front wheels by moving forward on the seat. Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incor- rect body movements, or too much speed for the sharpness of the turn may cause the MOTO-4 to tip. If the MOTO-4 begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throt- tle and steer to the outside of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your MOTO-4.CLIMBING UPHILL Use proper riding techniques to avoid ve- hicle overturns on hills. Be sure that you can maneuver your MOTO-4 well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose sur- faces, or obstacles that might cause you to lose control. POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur- faces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on steep for the ATV or for your al : Practice on smaller hills before attempt- ing large hills. Itis important when climbing a hill to make sure that your weight is transferred for- ward on the MOTO-4. This can be accom- plished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars.POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Own- er’s Manual. Always check the terrain carefully be- fore you start up any hill. Never climb hills with excessively slip- pery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the MOTO-4 around while you still have for- ward motion (provided you have the room to do so) and go down the hill. OW VGN POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner's Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owner's Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. OK — aIf your MOTO-4 has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to contin- ue up the hill, dismount the MOTO-4 on the uphill side. Physically turn the MOTO-4 around and then descend the hill. If you start to roll backwards, DO NOT use the rear brake to stop or try to put the MOTO-4 in gear. The MOTO-4 could easily tip over backwards. Instead, dismount the MOTO-4 immediately on the uphill side. 7:28 POTENTIAL HAZARD 1g backwards or improper- ly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock parking brake, after you are stopped. If you begin rolling backwards: Keep weight uphill. Never apply the rear brake while roll- ing backwards. Apply the front brake. When fully stopped, apply rear brake as well, and then lock parking brake.Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the pro- cedure described in the Owner’s Manu- 1-29RIDING DOWNHILL When riding your MOTO-4 downhill, shift your weight as far to the rear and uphill side of the MOTO-4 as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will al- low the engine compression to do most of the braking for you. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. Whenever possible, ride your MOTO-4 straight downhill. Avoid sharp angles which could allow the MOTO-4 to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear. POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner's Manual. Note: a special tech- nique is required when braking as you go down a hill. Always check the terrain carefully be- fore you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply ‘to one side. Go straight down the hill where possible.CROSSING A SLOPE Traversing a sloping surface on your MOTO-4 requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempt- ing to cross a sloping surface. Avoid slopes with slippery surfaces or rough ter- rain that may upset your balance. As you travel across a slope, lean your body in the uphill direction. It may be nec- essary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes be sure not to make sharp turns ei- ther up or down hill. If your MOTO-4 does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel. POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD. Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner's Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if Possible. When crossing the side of a hil Always follow proper procedures as de- scribed in the Owner's Manual.Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.CROSSING THROUGH SHALLOW WATER The MOTO-4 can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before enter- ing the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the MOTO-4. Drive slowly and carefully. POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that spec- ified in your Owner's Manual. 7-34 Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.Test your brakes after leaving the water. Do not continue to ride your MOTO-4 with- Sa EER out verifying that you have regained prop- _— After ig your MOTO-4 in water, be er braking ability. sure to drain the trapped water by remov- ing the check hose at the bottom of the air filter case. Wash the MOTO-4 in fresh wa- ter if it has been operated in salt water or muddy conditions. 1. Check hose 7-38RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the MOTO-4 or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the MOTO-4 as loss of control and damage to the MOTO-4 may result. A_WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a colli- sion. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obsta- cles, such as large rocks or fallen trees. When you go over obstacles, always fol- low proper procedures as described in the Owner's Manual.1-37SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the MOTO-4 may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery condi- tions, positioning your weight over the front wheels will sometimes help. 7-38 If the rear wheels of your MOTO-4 start to slide sideways, control can usually be re- gained (if there is room to do so) by steer- ing in the direction of the slide. Applying the brakes or accelerating is not recom- mended until you have corrected the slide.Nith practice, over a period of time, skill at sontrolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and contro! are reduced. Bear in mind that sliding maneuvers should al- ways be avoided on extremely slippery surfaces such as ice, since all control may be lost. 7-39 A_WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or slid- ing by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.WHAT TO DO FF... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. WHAT TO DO... © If your MOTO-4 doesn’t turn when you want it to: Bring the MOTO-4 to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the foot- board to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-23 ~ 7-24) If your MOTO-4 begins to tip while turn- ing: Lean more into the turn to regain bal- ance. If necessary, gradually let off the throttle and/or steer to the outside of the turn. (See pages 7-23 ~ 7-24) © If your MOTO-4 starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See pages 7-38 ~ 7-39) If your MOTO-4 can’t make it up a hill you are trying to climb: Turn the MOTO-4 around if you still have forward speed. If not, stop, dis- mount on the uphill side of the MOTO-4 and physically turn the MOTO-4 around. If the MOTO-4 starts to slip backwards DO NOT USE THE REAR BRAKE - the MOTO-4 may tip over on top of you. Dis- mount the MOTO-4 on the uphill side. (See pages 7-25 ~ 7-29)@ If your MOTO-4 is traversing a sloping surface: Be sure to ride with your weight posi- tioned towards the uphill side of the MOTO-4 to maintain proper balance. If the MOTO-4 starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the MOTO-4 is going to tip over, dis- mount on the uphill side. (See pages 7- 32 ~ 7-33) If your MOTO-4 encounters shallow wa- ter: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the MOTO-4 and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your MOTO-4 until you have re- gained adequate braking ability. (See pages 7-34 ~ 7-38) PGI Indicates a potential hazard that could re- sult in serious injury or death.oHo0200 PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment, and lubri- cation will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of ma- chine inspection, adjustment, and lubrica- tion are explained on the following pages. POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or can start fires. HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified. at Have a Yamaha dealer perform service if you are not familiar with machine ser- vice. onore0 Owner's manual and tool kit You are recommended to put this owner's manual and low-pressure tire gauge in the vinyl bag and always carry them in the storage box, Put the owner's tool kit in the space under the seat. 1. Tool kit 1. Owner's manual 2. Low-pressure tire gaugeThe service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive mainte- nance and minor repairs. The tools provid- ed in the Owner's tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. Note; If you do not have a torque wrench avail- able during a service operation requiring one, take your machine to a Yamaha dealer to check the torque settings and ad- just them as necessary. 82 CAN GIN} POTENTIAL HAZARD Operating this ATV with improper mod- ifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improp- er installation or use of accessories, All parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized Yamaha ATV dealer.epH00100 PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY eM ROUTINE 7) 3s )e)*e]a month |months|months|months|_year 7 7 Check valve clearance. oes + Adjust if necessary. ci o;o;° ~ Cheek condition. Spark plug + Clean or replace if necessary. o7yeofTol{eo}e Clean. Every 20-40 hours ae alee + Replace if necessary. (More often in wet or dusty areas.) 5 ~ Cheek idle speedistarter operation carey + Adjust if necessary. o7Teo};oleo 5 ~ Check fuel hose for cracks or damage. ele + Replace if necessary. o7Teolo Engine off = Replace (Warm engine before draining). o o[o]o Engine oll fiter Replace. ° °. ° Engine oll strainer | ~ Clean. ° © ° ~ Check oil level/il leakage. Final gear oi + Replace every 12 months. 9° 9 . 7 Check operationfiuid leakage/see NOTE page 8-4, Front brake + Correct if necessary. OEE . ~ Check operation. pea nare + Adjust if necessary. oO; o;e} ole . ~ Check operation. Ci + Adjust if necessary. ° o7Teolo Drive selectlever |» Check operation. alNCuIES safety system* + Adjust if necessary. 83Tem ROUTINE 7 3 € @ 7 Sno een eons Wheel _ See laeriansaero ot 3 0 0 5 > Check bearing assembly for looseness/damage. bearings + Replace if damaged. ° ° ° ° + Check toe-in. + Adjust if necessary. Fittings and fasteners* + Correct if necessary. + Check all chassis fittings and fasteners. o}|o;o}ojfo Battery* * Check specific gravity. + Correct if necessary. + Check that the breather pipe is working properly. | © | O | O | O | O * Itis recommended that these items be serviced by a Yamaha dealer or other qualified mechanic. NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Nor- mally check the brake fluid level and add fluid as required. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. Replace the brake hoses every four years, or if cracked or damaged. a4 A WARNING Indicates a potential hazard that could re- sult in serious injury or death.piosor Engine oil 1. a. b. NOTE: Engine oil level measurement Place the machine on a level place. Warm up the engine for several min- utes and stop it. . Remove the dipstick and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in. Wait a few minutes until the oil level set- tles before checking. d. Remove the dipstick and inspect the oil level. . The oil level should be between the maximum and minimum marks. If the level is low, add oil to raise it to the proper level. crankcase. 85 1. Dipstick 2. Maximum level mark 3. Minimum level mark 2. a. b. Engine oil replacement and oil filter cleaning. Place the machine on a level place. Warm up the engine for several min- utes and stop it. . Place a container under the engine. |. Remove the clamp.SO Seg 1 st 2. O-ting 3. Compression spring 4. Oil strainer 1. Clamp e. Remove the dipstick and drain plug to drain the oil. When removing the drain plug, the com- pression spring, oil strainer and O-ring will fall out. Take care not to lose these parts. f. Remove the oil filter cover and oil fil- ter. 861. Filter cover bolt (<3) 2. Filter cover g. Clean the oil strainer and oil filter with solvent. h. Inspect the O-ring and replace if dam- aged. . Reinstall the oil filter, O-ring, oil filter cover, oil strainer and drain plug. Tighten the drain plug to specification. 87 1g the drain plug, be sure 1g, compression spring Tightening torque: Drain plug (engine): 32 Nm (3.2 m-kg, 23 ft-lb) Filter cover bolt: 10 Nm (1.0 m-kg, 7.2 ft-lb)j. Fill the engine with oil and install the dipstick. Recommended oil: See page 5-7. Oil quantity: Periodic oil change: 2.4L (2.1 Imp qt, 2.5 US at) With oil filter replacement: 2.8 L (2.5 Imp qt, 3.0 US at) Total amount: 3.2L (2.8 Imp qt, 3.4 US qt) Be sure no foreign material enters the crankcas k. Warm up the engine for several min- utes at idle speed. Check for oil leak- age while warming up. If oil leakage is found, stop the engine im- mediately and check for the cause. ag 1 Oilgallery bolt 3. Oil pressure check . Put a cloth around the cylinder. b. Slightly loosen the oil gallery bolt in the cylinder head. c. Start the engine and keep it idling until oil begins to seep from the oil gallery. If no oil comes out after one minute, turn the engine off so it will not seize and find the cause. d. Restart the engine and check the oil pressure. e. After checking, tighten the oil gallery bolt to specification. 2. ClothTightening torque: Oil gallery bolt: 7 Nm (0.7 m-kg,5.1 ftlb) a Be sure to inspect the oil pressure after re- placing the engine f. Install the clamp. eoisa01 Final gear oil 1. Final gear oil measurement a. Place the machine on a level place. b. Remove the oil filler bolt and check the oil level. It should be up to the brim of the hole. If the level is low, add oil to raise it to the proper level. 89 CA Be sure no foreign material enters the final gear case. c. Install the oil filler bolt and tighten to the specified torque. Tightening torque: Oil filler bott: 23 Nm (2.3 m-kg, 17 ft-lb) 2. Correct oil level 1. Final gear oil 3. Filler bolt2. Final gear oil replacement a. Remove the final gear case cover. b. Place the machine on a level place. c. Place a container under the final gear case. d, Remove the oil filler bolt and the drain plug to drain the oil. 1. Drain plug e. Install the drain plug and tighten to the specified torque. Tightening torque: Drain plug (final gear case): 23 Nm (2.3 m-kg, 17 ft-lb) f. Fill the final gear case with oil.Recommended oil: SAE 80 API “GL-4” Hypoid gear oil Oil quantity: Periodic oil change: 0.19 L (0.17 Imp qt, 0.20 US qt) Total amount: 0.25 L (0.22 Imp qt, 0.26 US qt) Be sure no foreign material enters the final gear case. g. Install the filler bolt and tighten to the specified torque. Tightening torque: Filler bolt (final gear case): 23 Nm (2.3 m-kg, 17 ft-lb) h. Check for oil leakage. If oil leakage is found, check for the cause. i, Reinstall the final gear case cover. eos2000 Spark plug inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylin- der. Do not attempt to diagnose such prob- lems yourself. Instead, take the machine to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, you should replace the spark plug with one of the proper type. Standard spark plug: D8EA (NGK) or X24ES-U (DENSO)Before installing the spark plug, measure When installing the spark plug, always the electrode gap with a feeler gauge and _—_clean the gasket surface and use a new adjust to specification. gasket. Wipe off any grime from the threads and tighten to specification. Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Spark plug torque: 17.5 Nm (1.75 m-kg, 12.5 ft-lb) ® 1. Spark plug gaponean00 Air filter cleaning NOTE:. There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. 1. Check hose 1, Remove the seat. 2. Remove the air filter case cover. 1. Airfiter case cover 3. Remove the air filter element, and sep- arate it from the guide. 1. Air filter element 134. Wash the element gently but thor- oughly in solvent. PAW GNI POTENTIAL HAZARD Using low flash point solvents or gaso- line to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. 5. Squeeze the excess solvent out of the filter and let it dry. Do not twist the filter element when squeezing it. 6. Inspect the element. If damaged, re- place it. 7. Apply Yamaha foam air filter oil or other quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used. NOTE:. The element should be wet but not drip: ping. 8. Reinstall the element to the element guide. 9. Reinstall the element assembly and parts removed for access.NOTE: The air filter element should be cleaned ev- ery 20 ~ 40 hours. It should be cleaned and lubricated more often if the machine is op- erated in extremely dusty areas. Each time filter element maintenance is performed, check the air inlet to the filter case for ob- structions. Check the air cleaner rubber joint to the carburetor and manifold fit- tings for an airtight seal. Tighten all fittings securely to avoid the possibility of unfil- tered air entering the engine. Never operate the engine with the air filter element removed. This will allow unfil- tered air to enter, causing rapid engine wear and possible engine damage. Addi- tionally, operation without the filter ele- ment will affect carburetor jetting with subsequent poor performance and possi- ble engine overheati epveosor Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjust- ment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. How- ever, the idling speed may be performed by the owner as a part of the usual mainte- nance routine. The carburetor was set at the Yamaha fac- tory after many tests. If the settings are disturbed by someone without sufficient technical knowledge, poor engine perfor- mance and damage may result.epHao101 Idle speed adjustment NOTE; A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the en- gine to 4,000 to 5,000 r/min. The en- gine is warm when it quickly responds to the throttle. . Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in to increase engine speed, and out to decrease engine speed. Specified idle speed: 1,350 ~ 1,450 r/min 1. Throttle stop screw ovooror Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician.proto ov90000 Select lever safety system cable Throttle lever adjustment adjustment NOTE The select lever safety system cable ee ep stretches with use, resulting in improper Adjust the engine idling speed before ad- justing the throttle lever free play. function. To prevent this, the cable must be adjusted 1. Loosen the locknut. regularly. This adjustment, however, 2. Turn the adjuster until the throttle le- should be left to a Yamaha dealer. ver free play is 3 ~ 5 mm (0.12 ~ 0.20 in). 3. Tighten the locknut. 1. Locknut 2. Adjuster 1. Locknut 2. Adjuster a. 3~ 5mm (0.12 in ~ 0.20 in)